Industry 5.0 · 4 Days · In-Person + AR/VR Lab
Human-Centric Maintenance Excellence
A 4-day advanced program blending collaborative robotics, immersive AR/VR maintenance training, and human-factor principles to build resilient, future-ready maintenance teams.
01
Day 1 · Morning — Module 1
From Industry 4.0 to 5.0: The Human Return
- Industry 5.0 pillars: human-centricity, sustainability, resilience
- Why automation alone is not enough: the human value layer
- The new maintenance professional: skills taxonomy for 2025–2030
- EU Industry 5.0 framework and global regulatory landscape
- Case study: Cobot-assisted maintenance in automotive body shop
02
Day 1 · Afternoon — Module 2
Collaborative Robotics (Cobots) in Maintenance
- Cobot anatomy, payload capacities, and safety standards (ISO/TS 15066)
- Human-robot collaboration modes: co-existence, cooperation, collaboration
- Programming cobot-assisted inspection & lubrication routines
- Risk assessment and safe-speed monitoring setup
- Lab: Program a UR10e cobot for a simulated bearing inspection task
03
Day 2 · Morning — Module 3
AR/VR for Maintenance Training & Guided Repair
- Augmented vs. mixed vs. virtual reality: right tool for the right task
- Authoring AR work instructions with PTC Vuforia & Scope AR
- Remote expert systems: Microsoft Dynamics 365 Guides in practice
- VR simulation for high-risk maintenance scenario training
- Lab: Author and deploy an AR step-by-step pump overhaul guide
04
Day 2 · Afternoon — Module 4
Digital Twin Toolkit: Advanced Human-in-the-Loop Simulation
- Integrating human operator behavior into digital twin models
- Simulation of complex fault scenarios with operator decision trees
- Prescriptive maintenance: AI-generated action recommendations
- Closed-loop feedback: twin-to-operator real-time guidance
- Workshop: Extend Day 1 twin with human-factor decision overlays
05
Day 3 · Morning — Module 5
Human Factors, Cognitive Ergonomics & Error Prevention
- The Swiss cheese model applied to maintenance incidents
- Cognitive load theory in high-stakes maintenance environments
- Designing checklists, procedures & work instructions for human reliability
- Fatigue risk management and shift pattern optimization
- Workshop: Failure mode and human error analysis (FMHEA) exercise
06
Day 3 · Afternoon — Module 6
Psychological Safety, Well-being & Team Resilience
- Building psychologically safe maintenance teams
- Resilience engineering: anticipate, monitor, respond, learn
- Wearable health monitoring for frontline maintenance workers
- Burnout prevention and sustainable workload design
- Group activity: Team resilience self-assessment and action planning
07
Day 4 · Morning — Module 7
Sustainable & Circular Maintenance Practices
- Circular economy principles applied to asset management
- Energy efficiency monitoring and green KPIs for maintenance
- Extending asset life: remanufacturing and component refurbishment
- ISO 55001 alignment for sustainable asset management
- Case study: Net-zero maintenance strategy at a global manufacturer
08
Day 4 · Afternoon — Module 8
Capstone: Design Your Human-Centric Maintenance System
- Integrating 4.0 technology with 5.0 human principles: synthesis framework
- Your 1:1 coaching session: personal development plan review
- Capstone presentation: future-state maintenance operating model
- Peer review and expert feedback panel
- Certification assessment & alumni network onboarding